Quick lock system for joining and aligning tubes, conduits and junction boxes

ABSTRACT

A connecting system for quickly securing a hollow tube to a structure or to another hollow tube using a connector that has a housing with a tapered interior edge that operably engages a locking element positioned therein. When the tube is inserted into the locking element, the locking element holds and locks the tube in place in the connector. A guide ring may be provided within the connector to facilitate proper alignment of the tube within the connector and provide excellent electrical conductivity throughout the entire tube connecting system. One or more bearings may be provided as part of the locking element to facilitate initial tube insertion and then compression locking of the tube by the locking element. The connector can include a variety of structure engaging portions to allow the connector to be operably secured to a variety of structures such as electrical junction boxes, electrical conduits, tubes, armored cables, metal clad cables, flexible metal cables and the like.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 16/004,238, entitled “QUICK LOCK SYSTEM FOR JOININGAND ALIGNING TUBES, CONDUITS AND JUNCTION BOXES,” filed Jun. 8, 2018,which is a continuation of U.S. Non-Provisional application Ser. No.15/667,493, entitled “QUICK LOCK SYSTEM FOR JOINING AND ALIGNING TUBES,CONDUITS AND JUNCTION BOXES,” filed Aug. 2, 2017, now U.S. Pat. No.10,014,673, which is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 15/183,511, entitled “QUICK LOCK SYSTEM FOR JOININGAND ALIGNING TUBES, CONDUITS AND JUNCTION BOXES,” filed Jun. 15, 2016,now U.S. Pat. No. 9,762,041, which claims priority from U.S. ProvisionalApplication No. 62/181,753 filed Jun. 18, 2015. Further, U.S.Non-Provisional application Ser. No. 15/183,511 is acontinuation-in-part of U.S. Non-Provisional application Ser. No.14/547,059, entitled “Quick Lock Tube Securing System,” filed Nov. 18,2014, now issued U.S. Pat. No. 9,647,432, which claims priority fromU.S. Provisional Application No. 61/906,214, filed Nov. 19, 2013, all ofwhich are incorporated herein by reference in their entirety for allpurposes.

FIELD OF THE INVENTION

Embodiments of the invention are directed to elements, devices, tools,and systems comprised of the same that are used to connect tubes orconduits during the construction of buildings, server farms, and powerdistribution centers, and more specifically, to a system of elements foruse in connecting one or more tubes or conduits in an efficient andpractical manner by use of the inventive quick lock connector.

BACKGROUND

Hollow-tubed systems are used in a variety of applications. For example,Electrical Metallic Tubing (“EMT”) conduit systems include elongate,thin walled, non-threaded tubes that are usually formed of metal. EMTtubes are used to enclose electrical wires therein. Similar systemsinclude Rigid Metal Conduit (“RMC”), Galvanized Rigid Conduit (“GRC”),Intermediate Metal Conduit (“IMC”), Polyvinyl Chloride (“PVC”) conduit,Armored Cable (AC (BX)), Metal Clad Cable (MC), Flexible Metal Cable(FMC), Flexible Metallic Liquid Tight Conduit and Non-Metallic LiquidTight Conduit. Although often formed from metal, other materials such asplastic, fiber or fired clay can be used as well.

A typical EMT, RMC, or other conduit system usually includes electricaljunction boxes, a plurality of EMT tubes, and other electrical ormechanical elements that are joined together with fittings or couplingsto provide a continuous protected chamber for receiving and enclosingelectrical wires and their connections. These fittings or couplings jointhe tubes to the junction boxes, and also may be used to join two ormore sections of tubes together.

Currently, fittings or couplings for joining certain of these elementshave important limitations that render conventional approachesinadequate and/or less than optimal. For example, one common fittingincludes a connector body with an internally threaded compression nutscrewed onto a body of a fitting having external male threads. The endportion of a tube/conduit is received within the compression fitting,and a worker must tighten the compression nut to compress a steel glandring that is pre-installed between a compression fitting body andcompression nut in order to secure the tube within the fitting. Whileuseful in theory, in practice this design has disadvantages. Forexample, workers can over-tighten the compression nut sufficiently tostrip both female and male threads of a compression fitting; thisusually leaves a tube not secured or not locked in the desired positioncreated by the compression fitting. Alternatively, a worker canunder-tighten a compression nut to the male threads of a compressionfitting, thereby allowing the tube to become disconnected over time andexpose the wiring that within the tube.

In some cases, when an exterior thread on a compression fitting body orinterior thread on a compression nut are not threaded or machinedproperly, the exterior threads on the compression fitting body andinterior threads on the compression nut will not engage or mate well.This misalignment can cause scraping along the entire compressionfitting or a loose connection, thereby allowing the tube/conduit tobecome disconnected over time and expose the wiring within the tube.

Another common type of fitting includes a body with a perpendicularlymounted threaded set-screw. The end portion of a tube is slidablyreceived within the body of a set screw fitting, and a worker musttighten the set screw to secure the tube within the fitting. Whilesatisfactory in principle, in practice, workers may over tighten theset-screw, thereby placing excessive pressure on a localized portion ofthe tube. In some cases, this excessive pressure can damage or evenpierce the tube. Further, over-tightening one or two set-screws canstrip the female threads in the screw boss. Alternatively, a worker canunder-tighten the set-screw, thereby allowing the tube to becomedisconnected over time and expose the wiring within the tube.

A typical conduit system can include hundreds of these fittings, all ofwhich require hand tightening of each compression nut and set screw oneach fitting. The labor of performing this repetitive task can increasethe overall cost of a project and because of its repetitive nature, maybe the source of improperly connected tubes, conduits, or junctionboxes.

On the manufacturing side, it is necessary to make millions of thepieces that are part of these fittings; this typically requires asection of tube cut into a defined length to form a compression nut.After forming the compression nut, manufacturing workers tap each nutwith internal threads. In addition to forming and adding threads to thecompression nut, manufacturing a fitting requires that each nut besecured to a compression connector or to a compression coupling.Further, each compression connector or compression coupling is formed ina similar manner, with threads being formed on one end of each connectorand two threads being formed on each compression coupling. The number ofstages in the overall manufacturing process, combined with theassociated costs in terms of material and energy is relatively high andmay be difficult to justify for a less than optimal end product in someuse cases.

Set-screw type connectors or couplings require labor to punch holes andtap threads on each screw hole, thereby increasing the cost ofproduction. Millions of set-screw fittings and compression fittings(including the compression nuts) are currently manufactured each year.With each type of fitting being large and relatively heavy, there is arelatively large amount of energy used in the manufacture anddistribution (including transportation related expenses) of thesefittings. Another impact of the manufacture of conventional fittings ofthe types described arises because, typically, the couplings are zincplated. Given the relatively large size of conventional couplings andthe number manufactured, this means that a large amount of zinc platingis performed; this may have adverse effects on the environment.

Some efforts have been made to provide a snap-in securing system forjoining armored MC, AC (BX) and FMC cables to junction boxes and thelike. Examples of these Types of systems are found in U.S. Pat. No.3,272,539 to R. W. Asbury, Sr.; U.S. Pat. No. 3,858,151 to Paskert; U.S.Pat. No. 6,670,553 to Gretz; and U.S. Pat. No. 6,939,160 to Shemtov.Among the disadvantages of such conventional snap-in systems is thatthese systems cannot bear a significant weight or uncoupling forcebecause the snap-in components are made from spring steel formed intotabs or snap clips, and these tabs or clips engage a portion of thesurface of the armored MC, AC (BX), and FMC cables. As a result, in someapplications such snap-in systems cannot be used on EMT, RMC, RGC or IMCconduits or tubing because the design of these taps or clips cannotprevent EMT, RMC, GRC or IMC conduits from being pulled out of thesnap-in systems when a force is applied to the connectors.

Conventional snap-in fittings typically include a ferrule with one ormore annularly mounted tabs or cantilevered snap clips extendingtherefrom. As mentioned, conventional snap-in systems are designed to beused on MC, AC (BX), and FMC cables; such cables are typically formedfrom a coil of strip metal to produce an armored exterior surface withwires or cables protected inside the armored surface. The armoredexterior surface may have the shape of external threads with arelatively large gap between two threads. When the armored cables areinserted into the snap-in connectors, the tabs or clips are designed toopen. The tabs or clips stick out against the ends of the armored cablesand snap onto the external threads of the armored cables to prevent thecables from being pulled out of the connector. Note that the tabs orsnap clips operably engage only a portion of the surface of the armoredMC, AC (BX), or FMC cable(s) inserted into the connector. While theseconventional systems may prevent the need for set-screws in somefittings, they can become loose over time and they fail to provide a wayto assure that they are properly aligned when installed.

Despite the availability of several conventional forms of tubing joiningsystems, there remains a need for a quick-connecting tube engaging andjoining system that assists in obtaining the proper alignment of eachtube and operates to more evenly distribute the securing load around theentire circumference of a tube instead of to a localized region. Thisattachment technique provides a more secure and properly aligned methodof joining two hollow tubes or conduits together and/or joining a hollowtube or conduit to a junction box or other receptacle. Note further,that by distributing the securing load around the circumference of atube, less stress is put on the tube surface and connecting elements,thereby reducing potential sources of breakage, damage, faults, or othertypes of failures.

In addition, there remains a need for a tubing joining system that canprovide effective and reliable continuity of electricity or electricalsignals from a quick-lock connector to a junction box or from aquick-lock coupling to two or more sections of tubes that are part of asystem of tubes, conduits, and junction boxes.

Further, there remains a need for a tubing joining system that includesa securing fitting that is substantially less likely to beover-tightened or under-tightened than conventional devices, but insteadconsistently provides a more optimal securing force at each connectionpoint or region. This aspect operates to save time during installation,reduce the effort used in the installation process, and reduce thebreakage of parts. As an additional benefit, the manufacturing andon-site installation phases for the inventive system and methods arerelatively environmentally friendly compared to many conventionalapproaches.

Embodiments of the invention overcome these limitations or disadvantagesof conventional systems for coupling tubes or conduits to junctionboxes, either alone or in combination.

SUMMARY

The terms “invention,” “the invention,” “this invention” and “thepresent invention” as used herein are intended to refer broadly to allof the subject matter described in this document and to the claims.Statements containing these terms should be understood not to limit thesubject matter described herein or to limit the meaning or scope of theclaims. Embodiments of the invention covered by this patent are definedby the claims and not by this summary. This summary is a high-leveloverview of various aspects of the invention and introduces some of theconcepts that are further described in the Detailed Description sectionbelow. This summary is not intended to identify key, essential, orrequired features of the claimed subject matter, nor is it intended tobe used in isolation to determine the scope of the claimed subjectmatter. The subject matter should be understood by reference toappropriate portions of the entire specification of this patent, to anyor all drawings, and to each claim.

In one embodiment, the invention is directed to a hollow-tube connectingsystem that includes a connector element for securing a hollow tube to astructure (such as a junction box) or a coupling for securing two hollowtubes together. In one embodiment, the connector has a body with atapered interior edge and an opening for receiving the tube therethrough. Further, in some embodiments, a locking wedge or lockingelement with a tapered exterior surface is located within the connectorbody. In one disclosed embodiment, the locking wedge or element may havean opening and a plurality of spaced apart ball bearings inlaid inpreformed apertures on the locking wedge; the ball bearings andapertures function to restrict movement of the tube after it is receivedthrough the opening.

In one embodiment, the inventive system may include a guiding ringelement that functions to assist in aligning an inserted tube with thelocking wedge or locking element. In some embodiments, the guiding ringor another element may include a force supplying or resilient element(such as a coil spring, for example) that functions to provide a forcewhich acts to push the locking wedge or element into the properposition.

In some embodiments, when the tube is inserted into the connectoropening, the tube encounters the wedge or element and the plurality ofspaced apart ball bearings engage on the exterior surface of the tube.Further, the ball bearings move on the tapered interior edge of thebody, when the tube moves inward to the larger interior diameter of thetapered body. When a force is applied so as to urge the tube towards thesmaller interior diameter of the tapered body, the resulting reactionforce on the tube (caused by the engaged plurality of ball bearings onthe exterior surface of the tube and by ball bearings moving toward thesmaller diameter of the tapered interior surface on the connector body)which acts to hold/position/lock the tube in the connector. When thereaction force reaches a specific point (referred to herein as havingreached the self-locking point), the annular tube is locked inside thelocking wedge and connector body in the proper alignment.

By way of further explanation, in some embodiments, when an annular tubeis inserted into the tapered interior wall of the connector body, as thetube moves toward the larger diameter of the tapered connector body, itmoves relatively freely; however, when it moves toward the smallerdiameter of the tapered connector body, the increased reaction force(arising from movement of the ball bearings on the tapered interiorsurface of the connector body to a smaller diameter) operates to lockand hold the tube in place in the connector.

In some embodiments, the inventive system may include an element orelements that function to permit a user to disengage, disconnect orun-lock an annular tube or section of conduit that has previously beeninserted into a connector, coupler or locking element. In oneembodiment, the un-lock element or elements include or comprise anannular button, plug, or surface with a hollow central region. Theinside diameter of the hollow central region of the disconnect orun-lock element or mechanism is an open region through which a tube orconduit may pass. A lip or ridge on one end of the disconnect or un-lockelement or mechanism permits a pressure (such as applied by a user'sfingertips) to “push” the disconnect or un-lock element or mechanisminward against the biasing force provided by the resilient element,internal spring or other biasing material in the connector or coupler.When such a pressure is applied, the disconnect or un-lock element ormechanism moves slightly inward, thereby pushing the locking element(s)of the connector or coupler inward and permitting the release of thepreviously locked tube or conduit. In the absence of such an appliedpressure, a tube or conduit may be inserted through the central regionof the disconnect or un-lock element or mechanism and into the lockingelement or edge of the coupler or connector.

Note that in some embodiments or use cases, two of the inventiveconnectors may be formed on ends of a base structure to construct aninventive quick-lock coupling that uses substantially the same lockingsystem as described with regards to the connector; this coupling may beused to connect and lock two pieces of tubing, with one piece locked andaligned to each side of the coupling. Thus, by use of an embodiment ofthe inventive connector or coupling, a hollow tube may be connected toanother tube or to a junction box or similar element.

Other objects and advantages of the present invention will be apparentto one of ordinary skill in the art upon review of the detaileddescription of the present invention and the included figures.

FIGURE DESCRIPTIONS

Embodiments of the invention in accordance with the present disclosurewill be described with reference to the drawings, in which:

FIG. 1 is an exploded, isometric view of a quick lock fitting inaccordance with an embodiment of the invention, showing a tube operablysecured thereto and a possible connection to a junction box.

FIG. 2 is an exploded, isometric view of the quick lock fitting of FIG.1 showing a possible orientation relative to a tube.

FIG. 3 is an enlarged, isometric view of the quick lock fitting of FIG.1.

FIG. 4 is cross-sectional view of the quick lock fitting of FIG. 3,taken along line 4-4 of FIG. 3.

FIG. 5 is an isometric view of a tube engaging tapered, annular lockingwedge in accordance with an embodiment of the present invention.

FIG. 6 is a cross-sectional view of the tube engaging tapered, annularlocking wedge of FIG. 5 taken along line 6-6 of FIG. 5.

FIG. 7 is an exploded, isometric view of a tube engaging tapered,annular locking wedge in accordance with an alternative embodiment ofthe present invention showing a possible resilient ring operably securedthereto.

FIG. 8 is a cross-sectional view of the tube engaging tapered annularlocking wedge of FIG. 7 taken along line 8-8 of FIG. 7, and shown withthe resilient ring secured thereto.

FIG. 9 is an isometric view of a threaded base with collar in accordancewith an embodiment of the present invention.

FIG. 10 is a cross-sectional view of the threaded base with collar ofFIG. 9 taken along line 10-10 of FIG. 9.

FIG. 11 is an isometric view of a base in accordance with an embodimentof the present invention.

FIG. 12 is an isometric view of a base with two opposed collars inaccordance with an embodiment of the present invention.

FIG. 13 is an isometric view of an alternative possible base with twoopposed collars in accordance with an embodiment of the presentinvention.

FIG. 14 is an isometric view of a tapered, annular connector body inaccordance with an embodiment of the present invention.

FIG. 15 is a cross-sectional view of the connector body of FIG. 14 takenalong line 15-15 of FIG. 14.

FIG. 16 is an isometric view of an annular base forming a portion of theannular connector body of FIG. 14.

FIG. 17 is an isometric view of the tapered portion of the connectorbody of the annular connector body of FIG. 14.

FIG. 18 is a cross-sectional view of the quick lock fitting of FIG. 3,showing a possible alignment of a tube (shown in broken lines) beinginserted into the quick lock fitting.

FIG. 19 is a cross-sectional view of the quick lock fitting of FIG. 18,showing a possible attached position of the tube (shown in broken lines)in the quick lock fitting, in accordance with an embodiment of thepresent invention.

FIG. 20 is an isometric view of a quick lock coupling system inaccordance with an alternative embodiment of the present invention.

FIG. 21 is a cross-sectional view of the quick lock coupling system ofFIG. 20 taken along line 21-21 of FIG. 20, and showing a possibleorientation relative to two tubes (shown in broken lines).

FIG. 22 is an exploded view of the quick lock coupling system of FIG.20.

FIG. 23 is an isometric view of an alternative possible configuration ofthree quick lock fittings of the type shown in FIG. 1 on a T-shapedmember.

FIG. 24 is an isometric view of a possible configuration of twodifferent sized quick lock connectors of the type shown in FIG. 1 on athreaded rigid coupling.

FIG. 25 is an exploded view of a possible configuration of two of thesame sized quick lock connectors of the type shown in FIG. 1 on athreaded rigid coupling.

FIG. 26 is a cross-sectional view of the quick lock fitting of FIG. 1with an optional insert received therein for operably receiving thethreaded end of a tube (shown in broken lines), such as an Armored CableAC(BX), Metal Clad Cable (MC), Flexible Metal Cable (FMC) or the like.

FIG. 27 is an isometric view of the insert received within the quicklock fitting shown in FIG. 26, with a portion broken away to showcertain internal detail.

FIG. 28 is a cross-sectional view of an alternative embodiment of aquick lock fitting in accordance with an embodiment of the presentinvention.

FIG. 29 is a cross-sectional view of an alternative embodiment of theinventive quick lock fitting, showing a possible alternative wedgestructure with spring-biased bearings operably received therein, and apossible insert received within the fitting for receiving a threadedconduit.

FIG. 30 is a cross-sectional view of an alternative embodiment of thequick lock fitting showing the possible alternative wedge structure ofFIG. 29, and an alternative possible insert received within the fittingfor receiving a hollow cylinder therein.

FIG. 31 is a cross-sectional view of the insert of FIG. 30.

FIG. 32 is a cross-sectional view of the insert of FIG. 29. Note thatthe inner portion of alternative insert FIG. 29 may be formed in amanner so as to have internal threads or external threads.

FIG. 33 is a cross-sectional view of an alternative embodiment of theinventive quick lock fitting having a straight entrance and a sealingring secured at the entrance; the figure shows the wedge structure ofFIG. 29 operably receiving a tube within the fitting, with the sealingring at the entrance of the connector being used to make the connectorsubstantially water tight when receiving a tube into the locking wedgeand chamber of the connector.

FIG. 34A is an exploded isometric view of a possible configuration ofmultiple of the inventive quick lock fittings joined to a curved tube,in accordance with an embodiment of the invention.

FIG. 34B is an exploded isometric view of an alternative possibleconfiguration of multiple of the inventive quick lock fittings joined toa curved tube, with the tube having engaging flanges at its distal endsfor operably engaging the housing of the fitting.

FIG. 35 is a cross-sectional view of an alternative embodiment of theinventive quick lock fitting, showing the wedge structure of FIG. 29 anda second alternative possible insert received within the fitting forreceiving a threaded cylinder therein. Note that the hollow threadedcylinder shown in FIG. 35 is externally threaded, and that the hollowthreaded cylinder may be externally threaded or internally threaded.

FIG. 36 is a top view of the alternative wedge structure shown in FIG.29.

FIG. 37 is a bottom isometric view of the alternative wedge structureshown in FIG. 29.

FIG. 38 is a top isometric view of the alternative wedge structure shownin FIG. 29.

FIG. 39 is an exploded isometric view of an alternative possibleconfiguration for joining an embodiment of the inventive quick lockfitting to a curved tube, and a threaded section for connecting to ajunction box or the like.

FIG. 40 is a cross-sectional view of an alternative embodiment of theinventive quick lock tube securing system, showing an alternativelocking element structure with spring-elements mounted to a guiding ringand extending toward a bearing.

FIG. 41a is a cross-sectional view of an example of a guide ring with amounting hole and mounting taps.

FIG. 41b is a cross-sectional view of an example guide ring with mountedspring elements that may be used as part of an embodiment of theinventive quick lock tube securing system.

FIG. 42 is a cross-sectional view of a coil spring in a neutralposition, positioned with one end against the bottom surface of aguiding ring.

FIG. 43 is a cross-sectional view of a fully assembled quick lock tubesecuring system with a coil spring in a neutral position, positioned ontop of a bearing and positioned against the bottom of a guiding ring,and that may be used as part of an embodiment of the inventive quicklock tube securing system.

FIG. 44 is a cross-sectional view showing an alternative locking elementstructure with a bearing including a plurality of spaced apart rotatablebearings secured in the slots of a bearing structure wall, where thestructure to hold the bearings can be fabricated from metal, plastic orporcelain.

FIG. 45 is a cross-sectional view of a connector body with a straightportion at the entrance to the body.

FIG. 46a is a cross-sectional view of an annular ferrule that may besecured on top of the straight portion at the entrance of a connectorbody of the type shown in FIG. 40.

FIG. 46b is a cross-sectional view of a sealing sleeve or gasket with alip formed on the interior wall, and into which an annular ferrule maybe inserted.

FIG. 47 is a cross-sectional view of an alternative embodiment of theinventive quick lock tube securing system, showing an alternativelocking element structure with a coil spring, wherein the coil spring isneutrally positioned between a guiding ring and one or more bearings.

FIG. 48 is a view of an element that may be incorporated into anembodiment of the inventive quick lock tube securing system in order tofacilitate the removal or disengagement (disconnection or un-locking) ofa tube or conduit from a connector, coupler or locking element;

FIG. 49 is a cut-away view of a connector, coupler or locking elementthat includes the disconnection or un-locking element of FIG. 48 andwhich may be used in an embodiment of the inventive quick lock tubesecuring system; and

FIG. 50 is an exploded view of the elements or components of anembodiment of the inventive quick lock tube securing system whichincludes the disconnection or un-locking element of FIGS. 48 and 49.

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is describedherein with specificity to meet statutory requirements, but thisdescription is not intended to limit the scope of the claims. Theclaimed subject matter may be embodied in other ways, may includedifferent elements or steps, and may be used in conjunction with otherexisting or future technologies. This description should not beinterpreted as implying any particular required order or arrangementamong or between various steps or elements, except when the order ofindividual steps or arrangement of elements is explicitly described andindicated as being required.

Embodiments of the invention will be described more fully hereinafterwith reference to the accompanying drawings, which form a part hereof,and which show, by way of illustration, exemplary embodiments by whichthe invention may be practiced. This invention may, however, be embodiedin many different forms and should not be construed as limited to theembodiments set forth herein; rather, these embodiments are provided sothat this disclosure will satisfy the statutory requirements and conveythe scope of the invention to those skilled in the art.

One or more exemplary embodiments of the inventive rapid connectingsystem 40 for connecting tubes 42 to each other and/or to otherstructures (such as a junction box or receptacle) using an inventivequick lock connector 44 are shown in FIGS. 1-47, and described infurther detail herein.

General Construction

Referring to FIG. 2, an embodiment of the inventive connector 44 has aconnector body 46 with an opening 48 sized to slidably receive a tube orconduit 42 therethrough, and a tapered interior surface 50 that narrowstowards the opening 48. Inside the body 46 is a mating tapered lockingwedge 52 that may have, for example, six (or in other embodiments, moreor less) roller bearings 100 (preferably in the form of spherical steelballs), inlaid in spaced-apart preformed apertures 102. Locking wedge 52also includes or features an opening 54 for snugly receiving andengaging the exterior surface of tube 42. Locking wedge 52 also includesor features an annular guide ring 60 that operably engages the end ofthe tube 42 received therein. Note that in use, locking wedge 52 ispositioned at least partially interior to connector body 46 and that astube or conduit 42 is inserted, roller bearings 100 move or rotatewithin their respective apertures 102.

Typically for most conventional uses, connector 44 may be fabricatedwith materials suitable for use with a conventional conduit tube,including but not limited to: EMT, RMC, GRC, Rigid, IMC, PVC and armoredCable; AC (BX), Metal Clad Cable; MC and Flexible metal cable; FMC andFlexible Metallic Liquid Tight Conduit, and Non-Metallic Liquid TightConduit.

In operation or use, the end of tube 42 is engaged with or secured tolocking wedge 52 and guide ring 60 by an installer; this may beaccomplished by inserting the end of tube 42 into opening 48 inconnector body 46. The roller bearings 100 inlaid on the mating taperedlocking wedge 52 engage the exterior surface of tube 42. As they engagethe exterior surface and in response to insertion of tube 42, the rollerbearings 100 are caused to move along a portion of tapered interiorsurface 50 of connector body 46. This acts to prevent tube 42 from beingmoved backwards (such as might occur in an attempt to remove it fromconnector 44) to the smaller diameter regions of body 46. In someembodiments and uses, connector body 46 may be integrated with a basestructure 70 to form a quick lock connector unit, having the capabilityto be secured to another component 72, such as a junction box orreceptacle (as shown in FIG. 1).

Connector Body with Tapered Interior

As shown in FIGS. 1, 2 and 14-17, the body 46 of the inventive connectordefines a housing that encircles the end of tube or conduit 42 andprovides or defines a chamber 79 for receiving and enclosing (at leastin part) other components of connector 44 therein. Tube 42 preferablyhas a circular cross-section (although it may have other forms ofcross-sections, such as elliptical) and opening 48 in connector body 46is circular (or other suitable shape, such as elliptical) to slidablyreceive the end of tube 42 there through.

The interior surface 50 of connector body 46 is tapered in a manner soas to become smaller as it approaches opening 48, and body 46 is taperedin a manner so as to become bigger as it approaches base engagingportion 80. In some embodiments, the taper angle is preferably between 3to 25 degrees, inclusive. More preferably, for some applications, thetaper angle is between 8 to 12 degrees, inclusive.

As noted, connector body 46 includes a base engaging portion 80,positioned opposite opening 48. Base engaging portion 80 includesattachment elements or features for securing body 46 to base structure70, such as by means of compression, pressing, rolling, riveting,threading, rotating or the like. A shoulder 82 may be provided in baseengaging portion 80 for operably receiving and engaging guide ring 60therein, and connecting to base structure 70. Shoulder 82 may form anengaging portion on the connector body; shoulder 82 may be compressed orpressed by machine and dies to wrap over the collar of base 70 to makethe two pieces connect together. A guiding ring may be installed in theshoulder of the connector and just behind the base structure.

Connector body 46 is typically formed with substantially rigid materialssuitable for the particular type of tubing being used. For example, incases where the tubing is EMT tubing, the body may be formed withsuitable tubing that can properly function with EMT tube or the like.Note that connector body 46 is not required to be formed from suitabletubing, and may be formed (in whole or in part) from substantially rigidmaterials such as zinc die cast, malleable iron cast, gray iron orductile iron cast, or plastic molding.

Referring to FIG. 33, the fitting provides straight or substantiallyparallel entrances for receiving the distal end of the hollow tube 42.If desired, an annular insulating sleeve 800 may be operably securedaround the tube 42 and the housing of the fitting as shown, to form awatertight seal protecting the interior components from rain and thelike.

Referring now to FIGS. 40 and 47, in some embodiments, an annularferrule 58 (as also shown in FIG. 46(a)) may be secured on top of thestraight or substantially parallel entrance 77 (as also shown in FIG.45) of a connector body 46. This straight or substantially parallelentrance may provide better alignment of an inserted hollow tube 42 withone or more of the locking elements and guiding ring of an embodiment orembodiments of the invention. Such an entrance also provides a straightportion on the connector body 46 to which the annular ferrule 58 may besecured.

In this or another embodiment, in addition to (or in some cases insteadof) the annular ferrule 58, a sealing sleeve or gasket 806 (as shown inFIGS. 40 and 46(b)) with an interior lip may be installed on top of theannular ferrule, with the annular ferrule being inserted into theinterior lip of the sealing sleeve or gasket. Note that the interior lipon the sealing sleeve or gasket and the raised collar flange formed atthe entrance of the sealing sleeve or gasket may operate or function toprevent water or rain from entering connector body 46; this element orset of elements can therefore be used to effectively seal the connectorand substantially prevent the entry of rain or other sources of water,liquid, or moisture.

Tapered Locking Element/Wedge

As shown in FIGS. 2, 4-8, and 18-19, tapered locking element or wedge 52is used to receive, align, and fix in place tube 42. Locking wedge 52may be formed of resilient material (such as rubber, plastic or thelike), or may be formed of rigid material such as metal (e.g., steel,iron, zinc, copper, brass, cast iron or malleable iron or the like).Wedge 52 has a tapered exterior surface 90 and may have a plurality ofspaced apart roller bearings that are preferably substantially sphericalballs and are preferably made of steel, and that operably engage andmate with the tapered interior surface 50 of the connector body 46 (asshown in FIGS. 14 & 15). A through opening 92 (as shown in FIG. 5)extends through the tapered locking wedge 52 to define an annularlocking wedge wall 94. The opening 92 is sized and configured to receivethe end of the tube 42 as it is slid or moved through the opening 92.The tapered locking wedge 52 may be formed in one piece or in multiplepieces of resilient material such as rubber, plastic or the like, or amore rigid material such as metal (including steel, zinc, copper, brass,cast iron or malleable iron or the like), and the associated bearings.

A plurality of spaced apart bearings 100, such as rigid ball bearings,may be rotatably secured within apertures 102 in the wall 94 of thelocking wedge 52 (as shown in FIG. 5) such that the bearings extendinwardly to engage the exterior surface of the tube 42. Bearings 100 areable to move against the interior wall 50 of connector body 46 as tube42 is inserted and slid though the opening 92 in the locking wedge 52.Preferably, the bearings 100 include steel balls with each ball spacedan equal distance apart from the other balls along the circumference ofthe locking wedge wall, as shown in FIG. 6. The diameter of each steelball is preferably between 0.5 millimeter (mm) and 10 millimeter (mm),inclusive. The bearing with a tapered exterior wall can be formed aspart of the tapered locking wedge or as a separate piece working as apart of the tapered locking wedge.

Referring to FIGS. 7 and 8, the tapered locking wedge 52 may have a baseend 210 and an opposite tapered end 212; an optional resilient expansionring 214 may be operably received and placed within a groove 216 in thebase end 210 of the locking wedge 52. In an alternative embodiment, theexpansion ring 214 includes an opening 218 to allow the ring 214 to becompressed sufficiently to permit insertion into the groove. The ring ispreferably substantially circular and formed of spring steel or thelike. When released, it seeks to expand towards its neutral position,thereby urging the base end of the locking wedge 52 toward the connectorbody 46 and further holding the locking wedge in place within theconnector body 46. In some cases, the resilient materials are not firmor hard enough to maintain the opening of the wedge sufficiently toreceive a tube into the wedge. To prevent this problem, an expansionring just inside the edge of opening of wedge may be used to hold theopening of the wedge in a round and open position in order to receivetube.

Referring to FIGS. 29, 30, 33, and 35-38, an alternative embodiment of awedge 52′ is shown. With similar elements to those in the previouslydisclosed wedge 52 being like numbered, the alternative embodiment of awedge includes a plurality of spaced-apart elongate apertures 502appropriately sized to operably receive a resilient member (such as aspring 500 or the like) therein and at least one bearing 100. Theresilient member urges the bearing to a neutral position toward thetapered end of the wedge. In this embodiment, when tube 42 enters theopening of locking wedge 52, the exterior wall of tube 42 provides acompression force or pressure on the bearings (such as the steel ballsor other form of bearing). In response, the bearings push the resilientmaterials (such as a spring 500 or the like) to move towards the largerdiameter regions of the connector body. Due to the resilient nature of acoil spring, the material “pushes” or attempts to spring back when thebearings push the resilient materials toward the larger diameter regionsof the connector body. When a user attempts to pull tube 42 out of thelocking wedge toward the opening 48 of connector body 46, the resilientmaterial will act to push the bearings to move with the tube 42 towardthe opening 48 of connector body 46 (and thus towards the smallerdiameter regions of the tapered walls).

Referring to FIGS. 41(a), 41(b), 42, 43 and 44, another alternativeembodiment of a locking element 52″ that may be used in an embodiment ofthe invention is shown. With similar elements to those in the previouslydisclosed locking element 52 being like numbered in these figures, thealternative embodiment of a locking element 52″ is formed from multiplepieces and different types of structures or elements. Alternativeembodiment of a locking element 52″ includes a plurality of spaced apartbearing(s) 100, such as rigid ball bearings, which may be rotatable andsecured (i.e., rotatably secured) within slots 202 formed in the wall104 of the locking element 52″ (as shown in FIG. 44), where the bearingsextend inwardly to engage the exterior surface of an inserted tube 42.

In this alternative embodiment, there are multiple possible sources of aforce that may be used to urge a bearing or bearings into a desiredposition. The force supplying and/or resilient material(s) may include:(a) coil spring 230 with one end positioned against the bottom of theguiding ring (as shown in FIG. 42) and one end able to be positionedagainst the top of the bearings (as shown in FIG. 43); or (b) springelements 220 mounted on the bottom of a guiding ring 60 (as shown inFIGS. 40, and 41(b)). In each case, the force supplying and/or resilientelement(s) operate to urge the bearing(s) to a neutral position towardthe tapered end of the locking element/wedge.

In this embodiment or embodiments, and referring to FIGS. 40, 43 and 47,when tube 42 enters the opening of the locking element 52″, the exteriorwall of tube 42 provides a compression force or pressure on the bearings(such as the steel balls or other form of bearing). In response, thebearings push/urge the resilient materials (such as a coil spring 230 orspring element 220) to move towards the larger diameter regions of theconnector body. Due to the nature of coil spring 230 or spring element220 (or other resilient element), the force supplying or resilientelement(s) provide a resisting force that pushes or attempts to returnto its neutral position when the bearings push the resilient materialsor elements toward the larger diameter regions of the connector body.Thus, when a user attempts to pull tube 42 out of the locking element52″ toward the opening 48 of connector body 46, the resilient materialsor elements act to push the bearings to move with the tube 42 toward theopening 48 of connector body 46 (and thus towards the smaller diameterregions of the tapered walls of the connector body). This functions togrip, “lock” or otherwise hold the tube in the connector body.

It may be appreciated that when a tube is inserted within the opening inthe locking element/wedge, the resilient members allow the bearing todeflect back and out of the way toward base structure 70, therebyfacilitating insertion of the tube. However, the resilient memberstoward the base of the connector urge the bearings toward the taperedopening, thereby wedging the bearings between the housing and the tubeas previously described.

Guide Ring

As shown in FIGS. 2, 18, 19, & 30, the annular guide ring 60 providesstability and support for the tube 42. The ring 60 is preferably formedof a durable material such as metal, plastic or the like, and itincludes a ring opening 110 for snugly receiving the end of the tubetherethrough.

A plurality of spaced apart protrusions 112 or tabs extend from the ring60 towards the opening 110. The protrusions 112 may be angled away fromthe opening 48 in the connector body 46 so that they allow the tube 42to be inserted through the ring opening 110 and grasp or constrain thetube 42 should it be moved in a perpendicular direction away from theopening in the connector body 46. In one embodiment, preferably between4 and 12 protrusions 112 are spaced equal distance around thecircumference of the guide ring 60 as shown. Note that by contacting andgrasping the exterior surface of tube 42 through a plurality of spacedapart protrusions 112 or tabs that extend from the ring 60, this andother embodiments of the inventive connecting system and elementsprovide relatively superior electrical continuity and low electricalresistance between connector 44, tube 42 and a connected structure 72(FIG. 1) or the like. This feature is an important one for an electricalconnector or coupling, especially during circumstances such as anelectricity leak or a short between a wire and a power line.

The outer diameter of the guide ring 60 is appropriately sized to besnugly received within the base engaging portion 80 of the connectorbody 46. Accordingly, the ring opening 110 remains aligned along thelongitudinal centerline of the connector 44 and the opening 48 in thebody 46. The process of inserting an end of a tube through the opening48 in the body 46, then the opening 92 in the locking wedge, and thenthe opening 110 in the guide ring 60 urges the tube 42 into properalignment along the longitudinal centerline of the connector 44, untilencountering tube stop 123 (FIGS. 2, 9, 10, & 19) of base structure 70(FIGS. 2 and 9).

Referring to FIG. 41(a), an alternative embodiment of guide ring 60 isshown; in this embodiment, on the bottom flat surface 111 of guide ring60, mounting hole and mounting taps 113 may be formed for receivingspring elements 220 (as shown in FIG. 41(b)). When spring elements aremounted in this manner with (or to) guide ring 60 and the springelements extend toward the top of bearing(s) 100, the spring elementsoperate or function as the previously referred to “resilient material”of the locking element.

Base Structure

As shown in FIGS. 2, 9 and 10, the base structure 70 includes aconnector body-engaging portion 120 and an object-engaging portion 122.A shoulder 82 of the base structure 70 is operably secured to the baseengaging portion 80 of the connector body 46, thereby holding thetapered locking wedge 52 and guide ring 60 in place within the chamber79 (which is shown in FIGS. 14 and 15). The tube stop 123 (FIG. 12) onthe base structure 70 is formed by dies to receive the end of tube 42;after tube 42 passes through guiding ring 60, the tube stop 123 preventsthe end of tube 42 from being inserted any further into the connector.

Referring to FIG. 40, and to FIGS. 29, 30, 33, 35 and 43, an alternativeembodiment of the inventive system may include a rubber or plasticgasket 71 installed or positioned in between a locknut and base engagingportion 80 of the connector body 46. When an installer takes off alocknut from a quick lock securing system, the rubber or plastic gasket71 has one side positioned against the flat surface of an electricaljunction box and one side positioned against the base-engaging portion80; the gasket functions as a sealing ring or gasket and provides a sealto prevent water or rain from entering the electrical junction boxthrough the “knock out” portion or section of the electrical junctionbox.

The object-engaging portion 122 can be configured to enable mounting toa variety of structures (such as junction boxes or other containers).For example, the object engaging portion 122 can include a threadedelement 130 and locking nut 132 for securing the connector 44 through ahole or opening 134 in a conventional electrical junction box 72(FIG. 1) or the like, as shown in FIG. 1. When the object engagingportion of 122 does not include thread elements 130 and a lock nut 132,it can operate to secure the connector 44 by inserting the objectengaging portion 122 into a EMT tube, RMC, GRC, IMC and by welding orriveting element 122 to a EMT tube, RMC, RGC or IMC. This can be used tofabricate a piece of EMT tube, RMC, RGC Flexible Metallic Liquid TightConduit and Non-Metallic Liquid Tight Conduit or IMC into apre-fabricated connector or coupling attached conduit, which is thenready to connect to another piece of tube or conduit.

Alternatively, the object-engaging portion 122 can include two or moreconnector body engaging portions 120, as shown in FIGS. 20-25, therebyallowing at least two connectors 44 to be operably secured thereto; thispermits two tubes 42 to be joined together to make a quick lockcoupling, as shown in FIG. 22. In addition, and referring to FIG. 25, athreaded Rigid Coupling 150 can be used to operably secure the objectengaging portions 122 of two base structures 70, thereby joining twoconnectors 44 together. The die formed tube stop 123 (FIGS. 12, 20 & 21)at the center of the object engaging portion 122 of two base structures70 functions to stop ends of tubes 42 from further movement after thetwo tubes pass through respective guiding rings 60.

It can be appreciated that the tube 42 used need not be substantiallystraight. For example, the tube 42 can be T-shaped 71 (FIG. 23),U-shaped, or elbow shaped as shown in FIGS. 34A, 34B and 39. The tubescan include flanges and protrusions for operably engaging the housing asshown in FIG. 34B, or the tube can have a flange at one end and surfacesfor engaging other components, such as a housing for engaging the flangeof a threaded portion as shown in FIG. 39. In addition, a connectioncoupling 180 having different diameters on each end can be used to jointwo different sized connectors 44 together, as shown in FIG. 24.

Threaded Tube Attachment Structure

Referring to FIGS. 26 & 27, a threaded tube attachment structure 300that allows a threaded tube 42 to be operably secured to a connector 44is shown, where exemplar threaded tubes include armored cable and metalclad cables and the like. The attachment structure 300 includes anannular insert 302 that has a smooth outer surface 304 that is sized tobe operably connected to the connector 44 as previously described. Theinterior surface 306 of the insert 302 includes protrusions 308 orthreads (not shown) that are constructed (e.g., sized) to operablyengage the mating threads 310 of a threaded tube. Note that dependingupon the use case and fabrication, threaded tube 42 may be externallythreaded or internally threaded.

In a typical situation or use, an installer can mount a threaded tube 42to a connector 44 by first inserting the annular insert 302 into theconnector 44 and then threading the threads 310 of the tube 42 into theannular insert 302 in the connector 44. Alternatively, an installer canfirst thread the annular insert 302 onto an end of the threaded tube 42and then insert the threaded tube 42 with the annular insert 302installed into a connector 44.

Referring to FIGS. 29-32, alternative possible inserts 302′, 600 and 700are shown. These inserts operably engage either disclosed wedge 52 orwedge embodiment 52′, and are shown operably engaging wedge 52′ in FIGS.29, 30 and 33. Referring to FIG. 31, an elongate insert 600 having afitting engaging surface for operably engaging the fitting and aninterior wall portion for operably engaging the interior surface of ahollow tube is shown. Angled protrusions 606 may extend from theinterior wall portion. The protrusions are angled to deflect and allow atube to be inserted past them, but extend (or return to their normalposition) to resist removal of the tube once the tube operably engagesthe protractions.

Similarly, FIG. 32 shows a similar insert 700 that includes threadedportions for operably engaging the threads of a threaded tube, as bestshown in FIG. 35. A resilient portion may be positioned toward the baseand between the interior and exterior walls of the insert 700, therebyallowing a threaded tube 42′ to move or be slightly misaligned whilestill remaining secured within the fitting.

Example Process for Fabricating Component(s) of the InventiveConnector/Coupler

An example method of fabricating one or more of the components of theinventive connector using a machining process is now described. Notethat other methods, such as molding, may also be used to form one ormore of these components.

The connector body 46 is shown being formed from a section ofcylindrical tube 46 a in FIG. 16. The cylindrical tube 46 a is firstmachined to form a tapered segment 46 b, and then the shoulder ismachined into the tapered segment 46 b (FIG. 17) to form the finalconnector body 46 (FIGS. 14 & 15). Similarly, the base structure 70 maybe formed from a second section of cylindrical tube 70 a (FIG. 11). Thesecond section of cylindrical tube 70 a is machined to put one (FIG. 9)or two opposite (FIGS. 12 & 13) collars on the end(s), defining acollared cylinder 70 b (as shown in FIG. 13). Tube stops 123 (FIG. 12)may be machined into the collared cylinder to define a partiallymachined component 70 c (as shown in FIG. 12). Next, the attachmentstructures such as threads (or the like) are machined into the partiallymachined component to form the base structure 70.

The guide ring 60 may be formed from a substantially planar blank thathas been cut in to a predefined shaped, and then pressed to define theguide ring 60 with protrusions 112, as shown and previously described.

Use and Operation of an Embodiment or Embodiments of the InventiveSystem

Having described the elements of one or more embodiments of the presentinvention, their use and function are described in additional detail inthe following. An installer inserts an end of a hollow tube 42 into theopening 48 in the connector body 46 and pushes the end of the tube 42into the opening 46. The tube 42 operably engages a plurality of spacedapart bearings (preferably steel spherical balls) on the locking elementor wedge 52 (or one of its alternative embodiments, identified as 52″ or52′ in the figures); at the same time, the bearings inlaid in lockingwedge 52 engage and move along or on the tapered interior surface ofbody 46, while tube 42 continues to extend through the opening 92 in thelocking wedge and the opening 110 in the guide ring 60. The protrusions112 in the guide ring 60 hold the ring 60 onto the tube and the end oftube 42 stops at tube stop 123 formed inside base structure 70. Whentube 42 enters tapered connector body 46, which preferably has an 8 to12 degree tapered interior wall, and locking wedge 52 (or one of itsalternative embodiments), the steel ball bearings on wedge 52 engage onthe exterior surface of tube 42. If the wedge 52 is secured within thefitting, the resilient members allow the bearings 100 to move out of theway toward the base structure of the fitting when the tube is beinginserted.

When steel ball bearings on locking wedge 52 move on the taperedinterior surface of body 46, it creates a friction force between thesteel ball bearings and the tapered interior wall of body 46, which alsocreates and increases a reaction force on the exterior surface of tube42, thereby holding the tube 42 in the connector 44.

Note that if a force is applied in a direction that would normally actto pull tube 42 out of connector 44 (or toward opening 92 of lockingwedge or element 52 and/or opening 48 of tapered connector body 46),then the steel ball bearings move on the tapered interior surface ofconnector body 46 (along with tube 42) backward toward the smallerdiameter of tapered connector body 46. The resulting friction forcecreated by this movement causes a reaction force to compress against theexterior surface of tube 42; when the steel ball bearings move to theself-locking position, or when the reaction force reaches a point tohave enough compression against the exterior surface of tube 42 and thetapered interior surface of connector body 46, then the annular tube 42is locked in position inside of the connector 44. When a force isapplied in this direction, it functions to try to pull tube 42 out ofconnector 44; however, the plurality of steel ball bearings function to“lock” or hold tube 42 inside locking wedge 52.

As described, in a typical use, an installer may insert the end of atube 42 into a connector 44, with the guide ring 60 and tapered lockingwedge or element 52. When the tube 42 moves inwardly to a largerdiameter on the tapered interior surface of connector body 46, steelball bearings inlaid in the apertures of locking wedge 52 apply arestraining or holding force that is distributed throughout thecircumference of the tube 42, thereby holding the tube 42 in place. Iftube 42 is attempted to be moved backward (i.e., withdrawn) to a smallerdiameter of the tapered interior surface of connector body 46, the steelball bearings function to apply a locking force in locking wedge 52 thatholds or locks tube 42 in place.

As described herein, there is more than one type of locking element orwedge (such as those identified as element 52, 52′, or 52″ in thefigures) that may be used as part of the inventive system; in someembodiments, a wedge is formed of bearings and a resilient material,such as rubber or plastic. In some embodiments, a wedge is formed ofbearings (that may be subjected to a biasing force by a spring or otherstructure) and a rigid material, such as steel, iron, zinc, copper,brass, cast iron or malleable iron. In the type of wedge formed ofbearings and resilient material(s) (which may be constructed in onepiece or in multiple pieces), the wedge is able to move inside theconnector body (such as moving forward toward the larger diameter sideof the connector body or moving backward toward the opening 48 in thebody of connector 46). Note that the ability to undergo movement arisesfrom the resilient material used as part of the wedge or lockingelement.

When tube 42 enters the opening of locking element/wedge 52 (or otherembodiment), the exterior wall of tube 42 provides a compression forceor pressure on the bearings (such as the steel balls or other form ofbearing). In response, the bearings push the resilient materials (suchas rubber, plastic, coil spring or spring elements) to move towards thelarger diameter regions of the connector body. Due to the resilientnature of rubber, plastic, coil spring or spring elements, the material“pushes” or attempts to spring back when the bearings push the resilientmaterials toward the larger diameter regions of the connector body. Whena user attempts to pull tube 42 out of the locking wedge toward theopening 48 of connector body 46, the resilient material will act to pushthe bearings to move with the tube 42 toward the opening 48 of connectorbody 46 (and thus towards the smaller diameter regions of the taperedwalls).

Referring to FIGS. 29, 30 and 33, another alternative possible wedge 52′is shown; note that the elements in common with the previously disclosedwedge 52 are like numbered. The alternative wedge embodiment includes aplurality of spaced-apart elongate apertures 502 sized to operablyreceive a resilient (or biasing) member, such as a spring 500 or thelike therein, and at least one bearing 100. The resilient member urgesthe bearing to a neutral position toward the tapered end of the wedge.

When tube 42 is inserted into opening 48 in body of connector 46, theend of tube 42 enters the opening of locking wedge or element 52′; thisputs pressure on the bearing which causes the bearing 100 to push theresilient member (such as a spring 500) forward toward the largerdiameter regions of the tapered walls of the wedge and connector body.The bearing 100 is moving on both the tapered interior wall of connectorbody 46 and the exterior wall of tube 42, toward the larger diameterregions of the connector body 46.

In this alternative type of locking element or wedge, the elongate 502apertures are substantially hollow inside with the spring 500 sittinginside the pre-formed elongate apertures on the wedge and holding thebearings inside the apertures. When tube 42 enters the opening oflocking wedge 52′, it applies a compressing force on the bearings 100sitting inside the apertures 502. In response, the bearings move forwardtoward the larger diameter regions of the connector body 46. This occursbecause the springs are coil springs under pressure or an applied force;as a result, the springs will compress and make space for the bearingsto move within the elongate apertures.

When an attempt is made to remove the tube from the wedge (or if thetube is subjected to movement from another source, such as a lateralforce), the bearings and springs will move with the applied force, withthe springs inside the apertures moving toward the opening 48 ofconnector body 46.

In this embodiment of the locking element or wedge, the bearings andsprings may move slightly inside the connector in both directions; theycan move slightly toward the larger side of the connector body or movetoward the opening of the connector body (which is the smaller side ofthe connector body). At the same time, note that as the tube 42 entersthe opening of locking wedge 52 (or one of the other embodiments of thelocking wedge or element), the exterior wall of tube 42 becomes andremains engaged with the bearings (e.g., steel balls). The steel ballsor similar element(s) in the locking wedge move along the exteriorsurface of tube 42 and the tapered interior wall of connector body 46.The resilient materials or springs inside the apertures function tosupport the bearings and permit the movement slightly forward orbackward. Movement of the tube thus causes the bearings (i.e., steelballs) to move forward or backward because the exterior of the tube isengaged (in contact and maintained in contact) with these steel balls.As a result, the wedge itself can move slightly inside the connectorbody. In a sense, the wedge body is primarily a holding container forthe wedge elements or components (bearings and resilient materials, orbearings and springs).

When there is no tube being pushed into the connector, the bearings arein their neutral position inside the connector body. When a tube ispushed in, the bearings move toward the larger diameter regions of thetapered connector body (the tapered connector body is an importantfeature of the inventive system; it provides a mechanism for the lockingwedge to be able to operate). The bearings or steel balls arepre-installed in/on the locking wedge; when a pushing force is applied,the wedge moves toward the larger diameter regions of the connectorbody, which has more space or room for the bearings/wedge to fit.However, if a pulling force is applied, then the bearings (steel balls)on the wedge move toward the opening (smaller diameter) of the connectorbody and the reaction force causes the wedge to become fixed or held inthe connector body; this results because when the bearings move closeron the tapered interior wall of the connector body and the exteriorsurface of the tube to the reduced diameter regions (nearer to theopening of the connector body), the larger the reaction force that iscreated.

In some embodiments, the connector body may be formed using dies to havea tapered interior wall, with a tapering angle of between 3 and 25degrees. This means that inside the connector body, the walls are notvertical or straight; as an example, moving from the opening of theconnector body, the tapered interior wall may go from having a 3-degreeangle to a larger one further inside the connector body. Thus, thetapered interior wall of the connector body is getting larger movinginward from the opening of the connector body to the base structure.When a tube is pushed into the connector, the bearings will naturally beforced to move toward the larger opening areas of the tapered connectorbody.

When a pulling or removing force is applied to an inserted tube, thebearings move toward the smaller diameter regions of the taperedconnector body. When the pulling out force has caused the bearings tomove (with the help of resilient materials or springs) to the smallesttapered interior diameter or smallest position that the bearings (steelballs) are able to move, substantially no further bearing motion ispossible. Because the bearings are prevented from further motion by thetapered interior wall of the connector body and the exterior surface(wall) of tube, the bearings operate to lock the tube inside theconnector body.

One way to describe the behavior of the inserted tube in conjunctionwith the locking wedge is by considering the locking force as a reactionforce; when the reaction force from the pressure against thebearings/wall from the force attempting to remove the tube from theconnector exceeds the removal force, then the tube is locked inside theconnector body. This will occur (in theory) at the point where thebearings cannot fit any closer to the connector body opening because thetapered interior wall of the connector body and/or the exterior surfaceof a tube are prevented from being compressed any further on theelongated apertures because of the action of a resilient material orspring. Guiding rings 112 are for alignment and provide bettercontinuity between the tube and the connector or between two connectors.

As noted, the direction of movement of the bearings or the wedge isforward or backward (i.e., into or out from the connector body), and itsmotion is along the tapered interior wall of the connector body and theexterior surface of the tube. When the reaction force reaches a pointwhere it is greater than the pull out force (which is when the bearingson the wedge reach their furthest position on the tapered interior wallof the connector body or the smallest diameter of the tapered interiorwall it can reach), the force locks the tube inside the connector body.

In general, an embodiment of the inventive coupler or connector includesa body with a tapered interior and having an opening for a tube, and inwhich is positioned a locking wedge, that is in some embodimentscorrespondingly tapered to fit inside the body. The wedge includes anannular region in which are one or more apertures. Positioned in eachaperture is a bearing, typically a ball bearing. As described, in someembodiments, the annular ring may be formed of a resilient material,such as rubber or plastic or the like. The annular ring of resilientmaterial is subjected to a compressive force when a tube is insertedinto the connector body and forced against the bearings, thereby causingthe bearings to move towards the larger diameter regions of thebody/wedge. The resilient nature of the annular ring means that it willattempt to spring back or decompress, thereby applying a force againstthe inner wall of the body and the outer wall of the tube. When anattempt is made to remove the tube, the bearings may move slightly butwill become lodged against the inner wall of the tapered connector bodyand the exterior wall of the tube and in effect “locked” in placebetween the inner wall and the outer surface of the inserted tube. Thisacts to hold the tube and wedge in place in the connector body.

In a similar fashion, if the annular ring is made of a rigid or a morerigid material, then an embodiment of the locking element or wedge mayinclude an elongate aperture (or a plurality of apertures) in which isarranged a coil spring and a bearing attached to the spring. In thisembodiment, when a tube is inserted, it engages the bearing and forcesthe spring to compress. This permits the tube to enter the lockingwedge; however if a force is applied in an attempt to remove the tube,the spring acts to push the bearing back into its neutral position.However, because the bearing had moved to a region of the tapered bodyin which the diameter was larger in order to accept the tube, thelocking wedge and bearing are now substantially locked in place. Thisoperates to hold the tube in the locking wedge and hence in theconnector body. In general, either the (a) resilient material andbearing, or the (b) rigid material, spring, and bearing in combinationwith the tapered wedge/annular-ring/tapered interior wall of theconnector body provide a mechanism for permitting the tube to beinserted into the connector and held there in a manner which preventsremoval of the tube.

It can be appreciated that the combination of connectors 44, tubes 42and component engaging structures described herein provide a tubesecuring system (such as an electrical conduit assembly system) to bequickly, efficiently, cost effectively and easily constructed withoutthe need for securing compression nuts, set screws or the like. Thisincreases the utility of the inventive system, as well as reducingpossible assembly or alignment errors.

One skilled in the relevant art will recognize that numerous variationsand modifications may be made to the configurations described abovewithout departing from the inventive aspects described herein. Forexample, as shown in FIG. 28, the connector 44 may include an elongatedconnector body 46 to define a larger chamber therein. A spacer 400 maybe positioned within the elongated chamber along with the taperedlocking wedge 52 so as to secure the wedge 52 in place within thechamber and prevent it from moving when the tube 42 is inserted.Alternatively, the spacer 400 can be integrally formed or molded withthe wedge 52. Such modifications and additional embodiments can be madewithout departing from the scope of the present invention, as defined bythe appended claims.

In some embodiments, the inventive system may include an element orelements that may be used to facilitate the removal of a previouslyinserted tube or conduit from a connector, coupler or locking element.This element or mechanism for disengaging, disconnecting or unlocking atube or conduit from a coupler or connector provides users with a way toremove a tube or conduit that has been mistakenly, improperly orinadvertently connected to a coupler or connector. The unlock mechanismdescribed herein enables the safe removal of such a tube or conduitwithout the need to cut the tube or conduit or otherwise damage or wastematerial.

FIG. 48 is a view of an element 480 that may be incorporated into anembodiment of the inventive quick lock tube securing system in order tofacilitate the removal or disengagement (i.e., disconnection orun-locking) of a tube or conduit from a connector, coupler or lockingelement. In one embodiment, the unlock element or mechanism 480 is of anannular shape, and includes a substantially cylindrical body 482 with acentral opening or passage 484, and a ridge, lip, step, surface or rim486 to which a pressure or releasing force may be applied. Body 482includes a lip or raised portion 488 which acts to exert a force on theresilient element, spring or other biasing element in a connector orcoupler.

FIG. 49 is a cut-away view of an example of a connector, coupler orlocking element 490 that includes the disconnection or un-lockingelement of FIG. 48 and which may be used in an embodiment of theinventive quick lock tube securing system. As shown in the figure,disengaging or unlocking element 480 is inserted into the chamber of thetapered connector body 492, typically by being tamped or pushed intoconnector body 492 by a wood or rubber hammer through opening 493 ofconnector body 492. In one embodiment, an inner lip or step of theunlock mechanism (for example, element 488 of FIG. 48 or element 496 ofFIG. 49) has a flat surface, and is positioned so as to result in asmall space between it and bearing 495 of the locking system or lockingwedge. Note that in the absence of an applied force or pressure, unlockmechanism 480 remains in a neutral position in the tapered connectorbody 492, with a portion 491 positioned outside of connector body 492.Note that the exterior edge of the inner lip or step (element 488 ofFIG. 48 or element 496 of FIG. 49) of unlock button or mechanism 480 isslightly larger than the inner diameter of the entrance or opening 493of the tapered connector body 492. This functions to prevent the unlockmechanism 480 from slipping out of tapered connector body 492.

In operation, when an electrician or contractor uses their finger(s) toapply pressure or a force on the ridge, lip, step, surface or rim 486 ofunlock mechanism 480, the exterior edge of the inner lip or step 488/496of mechanism 480 moves inward and pushes against bearings 495, causinglocking system or locking wedge 494 to move toward the larger diameterend of tapered connector body 492. This causes the locking or retainingforce exerted by locking system or locking wedge 494 on the exteriorwall or surface of a previously inserted tube or conduit, and on theinterior tapered wall of connector body 492, to be reduced or released.As a result, an electrician or contractor can then safely remove thetube or conduit from a quick lock connector or a quick lock couplingwithout damage to the tube or conduit (i.e. without cutting off a tubeor conduit from a quick lock connector or coupling).

When an electrician or contractor removes his or her fingers (and theresulting inward pushing force) from the outer rim or step 486 of unlockbutton 480, this removes the applied force on the unlock mechanism. Whenthe applied force is removed, this also removes the force or pressure onthe flat surface of the inner step 496 of the unlock mechanism 480. As aresult, the resilient element, spring coil, spring system, or other formof biasing 497 of the locking system or locking wedge will exert a forcepushing back on the unlock mechanism 480 in a direction towards thesmaller diameter region or direction of the tapered connector body 492.Note that in this situation, the unlocking or disconnecting element 480is returned to and stays in its neutral position in tapered connectorbody 492. This will permit a tube or conduit to be inserted into centralopening or passage 484 of mechanism 480 and engaged with the lockingsystem or locking wedge.

FIG. 50 is an exploded view of the elements or components of anembodiment of the inventive quick lock tube securing system 550 whichincludes the disconnection or un-locking element of FIGS. 48 and 49. Asshown in the figure, an example embodiment of the quick lock securingsystem 550 includes the unlock or disconnect mechanism 480, a taperedhousing 552, an annular element and bearing 554, a resilient element,spring, spring system or other biasing element 556, a guide ring 558 andan element 560 for coupling the quick lock system to an electricaljunction box, etc.

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and/or were set forth in its entiretyherein.

The use of the terms “a”, “an” and “the”, and similar referents in thespecification and in the following claims are to be construed to coverboth the singular and the plural, unless otherwise indicated herein orclearly contradicted by context. The terms “having,” “including,”“containing” and similar referents in the specification and in thefollowing claims are to be construed as open-ended terms (e.g., meaning“including, but not limited to,”) unless otherwise noted. Recitation ofranges of values herein are merely intended to serve as a shorthandmethod of referring individually to each separate value inclusivelyfalling within the range, unless otherwise indicated herein, and eachseparate value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orclearly contradicted by context. The use of any and all examples, orexemplary language (e.g., “such as”) provided herein, is intended merelyto better illuminate embodiments of the invention and does not pose alimitation to the scope of the invention unless otherwise claimed. Nolanguage in the specification should be construed as indicating anynon-claimed element as essential to each embodiment of the presentinvention.

Different arrangements of the components depicted in the drawings ordescribed above, as well as components and steps not shown or describedare possible. Similarly, some features and sub-combinations are usefuland may be employed without reference to other features andsub-combinations. Embodiments of the invention have been described forillustrative and not restrictive purposes, and alternative embodimentswill become apparent to readers of this patent. Accordingly, the presentinvention is not limited to the embodiments described above or depictedin the drawings, and various embodiments and modifications can be madewithout departing from the scope of the claims below.

What is claimed is:
 1. A hollow-tube connecting system comprising: ahollow tube; a connector for securing the hollow tube to a structure,the connector further comprising; a connector body having a taperedinterior surface, the tapered interior surface causing the interior ofthe connector body to vary from a smaller diameter to a larger diameter,the interior surface defining a chamber, the connector body having anopening into the chamber for receiving the hollow tube, the openingbeing located at one end of the connector body, the one endcorresponding to the smaller diameter of the interior of the connectorbody; a locking element having a tapered exterior surface and positionedwithin the chamber of the connector body, the locking element having anopening for receiving the hollow tube and including an annular elementin which are included one or more bearings, wherein inserting the hollowtube into the opening of the connector body and then into the lockingelement urges the one or more bearings to engage the tapered interiorsurface of the connector body and the exterior surface of the insertedhollow tube, thereby increasing the hollow tube's resistance to beingremoved from the connector body, and further, wherein when the insertedhollow tube is attempted to be withdrawn from the connector body throughthe opening, the locking element moves toward the end of the connectorbody having the smaller diameter of the interior of the connector bodyand acts to increase a force locking the hollow tube inside theconnector body; an unlocking or disconnecting element to which a forcemay be applied, the applied force causing the annular element andresilient element to move inward towards the larger diameter from thesmaller diameter of the tapered interior surface of the connector body,thereby decreasing or releasing the locking force on the hollow tube anddecreasing the tube's resistance to being removed from the taperedconnector body; and a structure engaging portion operative to secure theconnector to the structure.
 2. The system of claim 1, wherein theannular element includes a plurality of apertures.
 3. The system ofclaim 2, wherein a bearing is secured within each of the plurality ofapertures.
 4. The system of claim 3, wherein each bearing is a ballbearing having a diameter between 0.5 millimeter (mm) and 10 millimeters(mm), inclusive.
 5. The system of claim 1, further comprising a guidering positioned within the chamber, the guide ring having an opening forreceiving the end of the hollow tube and an outer diameter sized toengage the interior surface of the connector body and operative to holdthe guide ring substantially parallel with the connector body opening.6. The system of claim 5, wherein the guide ring includes a plurality oftabs extending toward the center of the ring and angled away from theconnector body opening.
 7. The system of claim 1, wherein the hollowtube is an electrical conduit.
 8. The system of claim 7, wherein theelectrical conduit is selected from the group consisting of ElectricalMetallic Tubing, Rigid Metal Conduit, Galvanized Rigid Conduit,Intermediate Metal Conduit, Polyvinyl Chloride conduit, plastic, fiberand fired clay.
 9. The system of claim 1, wherein the structure engagingportion includes a threaded element and nut for securing the connectorto a hole in an electrical junction box.
 10. The system of claim 1,wherein the structure engaging portion includes two connector engagingportions for operably securing two connectors together.
 11. The systemof claim 1, wherein the tapered interior surface of the connector bodyhas a taper angle between 3 to 25 degrees, inclusive.
 12. A connector orcoupler for use in joining a hollow tube to a structure or to a secondhollow tube, comprising: a connector body having a tapered interiorsurface, the tapered interior surface causing the interior of theconnector body to vary from a smaller diameter to a larger diameter, theinterior surface defining an interior chamber, the connector body havingan opening into the interior chamber of the connector body for receivinga hollow tube, the opening being located at one end of the connectorbody, the one end corresponding to the smaller diameter of the interiorof the connector body; a locking element having a tapered exteriorsurface and positioned within the interior chamber of the connectorbody, the locking element having an opening for receiving the hollowtube, wherein inserting the hollow tube into the connector body openingand then into the locking element urges the tapered exterior surface ofthe locking element against the tapered interior surface of theconnector body and increases the hollow tube's resistance to beingremoved from the connector body, and further, wherein when the insertedhollow tube is attempted to be withdrawn from the connector body throughthe opening at the smaller diameter of the connector body, the lockingelement moves toward the smaller diameter of the interior surface of theconnector body and acts to increase a force preventing removal of thehollow tube, wherein the locking element further comprises an annularelement positioned to receive the hollow tube when the hollow tube isinserted into the connector body, the annular element including aplurality of apertures; and a bearing secured within each of theapertures; and an unlocking or disconnecting element to which a forcemay be applied, the applied force causing the annular element to moveinward towards the larger diameter from the smaller diameter of thetapered interior surface of the connector body, thereby decreasing orreleasing the force on the hollow tube and decreasing the tube'sresistance to being removed from the tapered connector body.
 13. Theconnector or coupler of claim 12, further comprising a guide ringpositioned within the chamber, the guide ring having an opening forreceiving the end of the hollow tube and an outer diameter sized toengage the interior surface of the connector body and operative to holdthe guide ring substantially parallel with the connector body opening.14. The connector or coupler of claim 13, wherein the guide ringincludes a plurality of tabs extending toward the center of the ring andangled away from the connector body opening.
 15. The connector orcoupler of claim 12, wherein the hollow tube is an electrical conduit.16. The connector or coupler of claim 15, wherein the electrical conduitis selected from the group consisting of Electrical Metallic Tubing,Rigid Metal Conduit, Galvanized Rigid Conduit, Intermediate MetalConduit, Polyvinyl Chloride conduit, plastic, fiber and fired clay. 17.The connector or coupler of claim 12, further comprising a structureengaging portion, wherein the structure engaging portion includes athreaded element and nut for securing the connector to a hole in anelectrical junction box.
 18. The connector or coupler of claim 17,wherein the structure engaging portion includes two connector engagingportions for operably securing two connectors together.
 19. Theconnector or coupler of claim 12, wherein the tapered interior surfaceof the connector body has a taper angle between 3 to 25 degrees,inclusive.
 20. The connector or coupler of claim 12, wherein eachbearing is a ball bearing having a diameter between 0.5 millimeter (mm)and 10 millimeters (mm), inclusive.